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Since my first post has now ended horribly, let's try this again.  I had wrote up a big first post giving my background but I guess my session timed or for whatever reason and it was lost. So the abridged version of what I said is this. ...I what at a engine bearing manufacturer, in the process we weld one coil of metal to the next to have a continuous metal strip at all times.  We weld .032-.197 steel and .045-.145 alloyed aluminum with tin and other "stuff" added in.  We use a lincwelder aircraft 250 for steel and a lincoln square wave 255 for aluminum.  I constantly have to deal with Co-workers that have no clue to the tig process and constantly grind the electrodes perpendicular to the grinder and feel the need to crank the argon up to at least 35cfh. I've tried showing them in writing the right way. Still they continue.
Reply:Now a question,  the aluminum we weld, as mentioned,  contains alot of tin and other add ins, silicate being one.  The material is heat treated before it gets to us. On some "blends" of aluminum there are issues with the haz becoming very brittle.  We only have a minute or two to cut, butt up the material, weld and send it on its way.  Me personally,  I try to at least brush the heavy scale off of the weld area and keep everything as clean as possibly in the sport time we have.  Anyone have any ideas that may help more?
Reply:First off welcome to the site....Some really cool guys on here with lots of knowledge......That said I'm not really sure I understand what your asking? In regards to your help sit them down and explain that their out the door if they don't  figure it out.....Lots of welders out of work these days....Since you seem to be time allotted for your cleaning processes maybe it needs some adjustment .........Your going to find that the largest majority of posts HERE  consist of Pictures and ever changing results.......Good luck with your deal                                                                                                                                          BC  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by B_CFirst off welcome to the site....Some really cool guys on here with lots of knowledge......That said I'm not really sure I understand what your asking? In regards to your help sit them down and explain that their out the door if they don't  figure it out.....Lots of welders out of work these days....Since you seem to be time allotted for your cleaning processes maybe it needs some adjustment .........Your going to find that the largest majority of posts HERE  consist of Pictures and ever changing results.......Good luck with your deal                                                                                                                                          BC
Reply:Find out what brand filler you are using and call the tech support for that brand.walk them through what you are doing and your allotted time. See what they say.
Reply:You got a WPS to work from?If so what is it?  Filler and cover gas in particular.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Some really fast wetting filler is Maxal's new 4943 alloy. It is not dependent on base metal dilution for strength.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Although those sound like great ideas, the company probably isn't going to try different fillers. And I'm not sure what wps is but I'm assuming it is basically welding instructions, but no, they don't.  Even though there can end up being alot scrap and downtime cost because of a bad weld,  it's not a big concern to the higher ups. That being said I'm just trying to get some info to help make the best welds possible with the time and equipment I have available,  and try to help others in our department make the best welds that they can as well.
Reply:The fact that you're asking around tell's me you're wrestling with management bottom line issues.I believe your best hope is to bring these issues up the ladder.maybe you're getting your ducks lined up first - good on yaIn my experience, do it right the first time, you'll save money and more importantly, customers.If management doesn't care, have a backup employment planluck,greg
Reply:A WPS is the proven recipe that all welding on that part is followed. It ensures that the same procedures are followed every time. Only one person should be allowed to change the WPS. Why can't you challenge management. Obviously they came up with the procedure, and it does not always work. So what filler do you use?Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:We are using 4043 filler but the brand is unknown.  And as for a proven procedure to follow to my knowledge there had never been one made up.  The only reference we have is for our steel welds, and that is just to give you and idea of voltage and current for the thickness of material your welding. Even that info is wrong. The welds that we do is only to keep the machine running. The only welds that are critical welds are done by robot with lasers. It would make it easier on everyone and save the company money in the long run if everyone would at least try to make the welds the way they should be made. One of the guys has had more welds break going through the mill than any two others combined. I will see if I can post some pics of what I deal with. Most of you when you see the condition of the electrodes and they way most grind them would probably refuse to work here. That's one reason I swap out electrodes when I work a particular section with one I've ground.
Reply:This is the only welding guide that we have.
Reply:Got it. 4043 is horrible brittle, and has much less ductility than 5356. It wets a bit better because of the silicon but not worth it if it cracks right off. 4043 is dependent on base metal dilution for strength, and your coils are not very good candidates for quality welds. 4043 is a poor choice. Even 1100 alloy would be a better choice for ductility than 4043.The reason I suggest 4943 is it is bridges the gap between 4043 and 5356 for strength and ductility. It also wets like no tomarrow. Where are you located? And start writing down preferred settings for yourself if not the company.Last edited by shovelon; 09-26-2013 at 04:09 PM.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Those settings in that picture is actually for our steel welder (WWII era) lincwelder aircraft 250. I found a manual for it online,  only one paragraph to tell you how to use it.  I guess they figured the military would come up with their settings anyway.  The basics of how to set up that welder is thinner metal,  higher voltage and lower current.  Thicker metal,  lower voltage and higher current. Located in Blacksburg,  va. I did come up with some settings for myself for the aluminum welding, that is the paper that I attached. The one at work is more complete.
Reply:This is a practice weld I had made before I started taking a wire brush the the joint first.For some reason I got two pics of the same weld. Attached ImagesLast edited by Dsmabe; 09-26-2013 at 09:59 PM.
Reply:Two pics, one with flash and one without.  One on the end is a new electrode that I sharpened for aluminum, the others are examples of used ones that co-workers made.
Reply:Looks like to me ALL were ground wrong.....The grind/Sand lines are going around the tungsten as apposed to inline......It makes for hard starting with low amp settings.Also the test weld has a ton of dirt in it?  What size tungsten are you using and cup configuration?1/8 in. Tungsten is way big for what your doing if  thats what your usingChemical cleaning might be in order for better results....Last edited by B_C; 09-27-2013 at 01:25 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Your welders need some class room time, their just costing your company money...Try hiring REAL TIG WELDERS....Dressing a tungsten is the FIRST thing you learn to do.....  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Attachment 502941This is 4943 as mentioned above......Last edited by B_C; 09-27-2013 at 01:36 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:The one far left I ground so the lines would be with the length of the tungsten. Then I used emery cloth to remove any lines from grinding to hopefully remove any contamination left by the grinder since it gets used for everything. #6 cup, 2% thoriated 1/8". I agree the tungsten is too big but I'd never get people to stick with a smaller tungsten.  So I make do with 1/8th. Since that picture I brush all joints before welding and it had helped,  but you still get some contamination. I am fairly certain the little bit of contamination I'm getting now is the parent metal itself.
Reply:Welding is only a small portion of what we do, I Believe that as long as downtime and scrap are not excessive,  higher ups are not concerned with  the welds quality on what we do as it had no end affect on the material produced.
Reply:On a side note, I do enjoy welding and know that if I could get certified and get in a actual welding position somewhere, I could make at least what I am now, most likely more.  One thing that had made me think of it is I work about 30 minutes from home.  While if I was certified to weld I could apply for a couple plants within walking distance from my house. How hard is it to get certified and how much would it cost.  I still have my Montgomery G I bill from the military that should cover already some if now all depending on how much it would cost.
Reply:This is the same welder we use for steel
Reply:another question,  what causes the electrode to do this?  Aluminum weld, lincoln square wave tig 255 transformer machine.  Auto balance,  122 amp .085" material.  1/8" 2% thoriated ground to truncated tip.
Reply:Originally Posted by DsmabeThis is the same welder we use for steelThis weld was brushed front and back, chemical cleaned front and back. Filler rod wiped down and still showing contamination in the weld.  Unless someone has another opinion, I think it's safe to say contamination is from the parent metal itself.
Reply:Id say that's a pretty accurate description from my understanding.